Tools Required

1. Remove the vent pipe.



2. Remove the clutch housing bolts and the clutch housing.



3. Remove the clutch lever pivot nut and the clutch fork.



4. Using the transmission adapter bolts (163) install the J 39430 . Refer to

   Shift Shaft and Clutch Housing

   
   
   
5. Mount the transmission on a workbench using the J 3289-20 .
6. Rotate the transmission into a horizontal position, shifter up.
7. Remove the transmission drain plug and drain the transmission fluid.
8. Shift the transmission into neutral (N).



9. Remove the shift control bolts and the shift control assembly.
10. Inspect the isolator cup for wear.
11. Replace the rear offset shift lever if the isolator cup is loose or if the lever is excessively worn.

1. Remove the rear offset shift lever roll pin.



2. Remove the rear offset shift lever assembly.



3. Remove the rear extension housing bolts and the rear extension housing.

Tools Required

1. Rotate the transmission vertically.
2. Remove the sealing ring.



3. Remove the front speedometer sensor gear retainer ring.



4. Remove the speedometer sensor gear. Use the J 8433 and the J 39431 .



5. Remove the rear speedometer sensor gear retainer ring.

1. Remove the rear bearing retainer ring.
2. Remove the spacer.
3. Remove the mainshaft rear roller bearing.
4. Remove the spacer.



5. Remove the retainer ring.
6. Remove the reverse gear thrust washer.
7. Remove the reverse gear.
8. Remove the reverse gear caged needle bearing.
9. Remove the wave washer.
10. Remove the reverse gear synchronizer blocking ring.

1. Remove the reverse synchronizer retainer ring.



2. Remove the reverse shift fork retainer ring. Discard the retainer ring.



3. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.



4. Remove the following parts in order:

4.1.	The thrust washer

4.2.	The reverse synchronizer assembly and the shift fork

Tools Required

Remove the 5TH/6TH speed driven Gear. Use the J 8433 and the J 39431 .

1. Remove the 5th/6th speed shift fork retainer ring.



2. Rotate the transmission in the horizontal position with the guide plate up.
3. Remove the countershaft extension assembly with the 5th/6th speed shift fork.

1. Remove the computer aided gear select solenoid.



2. Remove the shifter cover plate retainer bolts.
3. Remove the shifter cover plate.



4. Remove the shift detent assembly.



5. Remove the front offset lever roll pin.



6. Remove 8 of the 10 adapter plate to transmission case bolts.
7. Rotate the transmission into the vertical position.



8. Remove the last 2 adapter plate to transmission case bolts.
9. Remove the shift lever guide bolts.



10. Remove the magnets from the transmission case.



11. Remove the transmission case and the front offset lever together as follows:

11.1.

Slide the transmission case up and off of the gear clusters and the shift shaft components.

11.2.

Hold the offset lever against the guide plate in order to prevent the release of the detent ball and the spring.

1. Remove the detent guide plate attaching bolts.
2. Remove the detent guide plate.

1. Rotate the 5TH/6TH and the reverse shift shaft levers off the shift interlock plate.
2. Remove the 5TH/6TH and the reverse shift shaft assembly.



3. Remove the countershaft. Lift up the mainshaft enough in order to remove the countershaft.



4. Remove the mainshaft and the shift shaft components as an assembly.
5. Remove the shift shaft assembly from the mainshaft.



6. Remove the 4TH speed gear blocking ring and the input shaft.

Tools Required

1. Remove the adapter plate bolts (1) and (2).



2. Install the J 44395 .
3. Mount the transmission on a workbench using the J 3289-20 .
4. Rotate the transmission into a horizontal position.
5. Remove the transmission drain plug and drain the transmission fluid.
6. Shift the transmission into neutral (N).



7. Remove the rear extension housing bolts and the rear extension housing.

1. Remove the rear bearing retainer ring.
2. Remove the spacer.
3. Remove the mainshaft rear roller bearing.
4. Remove the spacer.



5. Remove the retainer ring.
6. Remove the reverse gear thrust washer.
7. Remove the reverse gear.
8. Remove the reverse gear caged needle bearing.
9. Remove the wave washer.
10. Remove the reverse gear synchronizer blocking ring.

1. Remove the reverse synchronizer retainer ring.



2. Remove and discard the reverse shift fork retainer ring.



3. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.



4. Remove the following parts in order:

4.1.	The thrust washer

4.2.	The reverse synchronizer assembly and the shift fork

Tools Required

Remove the 5th/6th speed driven gear. Use the J 8433 , the J 39431 and the J 39431-4.

1. Remove the 5th/6th speed shift fork retainer ring.



2. Rotate the transmission in the horizontal position with the guide plate up.
3. Remove the countershaft extension assembly with the 5th/6th speed shift fork, 6th speed gear bearing spacer, 6th speed drive gear, and caged needle bearing. The 6th speed gear bearing spacer will slide out during removal of the countershaft extension assembly.

Tools Required

J 41099 Skip Shift Sensor Remover/ Installer

1. Remove the computer aided gear select solenoid.



2. Remove the reverse lockout solenoid from the reverse lockout body. Use the J 41099 .



3. Remove the reverse lockout assembly bolt and the reverse lockout body.



4. Remove the shifter cover plate retainer bolts.
5. Remove the shifter cover plate.



6. Remove the shift detent assembly.



7. Remove 9 of the 11 adapter plate to transmission case bolts.
8. Rotate the transmission into the vertical position.



9. Remove the last 2 adapter plate to transmission case bolts.
10. Remove the shift lever guide bolts.



11. Remove the magnets from the transmission case.



12. Remove the offset lever roll pin.



13. Remove the transmission case and the offset lever together as follows:

13.1.

Slide the transmission case up and off of the gear clusters and the shift shaft components.

13.2.

Hold the offset lever against the guide plate in order to prevent the release of the detent ball and the spring.

13.3.

Remove the offset lever from the transmission case.

1. Remove the detent guide plate attaching bolts.
2. Remove the detent guide plate.

Caution: The reverse lockout assembly is under spring pressure. Exercise caution when removing the retainer ring, as bodily injury may result.

1. Remove the O-ring (8) from the body (1).
2. Remove the retainer ring (7) from the body (1).
3. Remove the reverse lockout inner spring (2).
4. Compress the reverse lockout plunger (6) and the collar (4) in a vise and remove the retainer ring (3).
5. Remove the reverse lockout plunger (6).
6. Remove the reverse lockout outer spring (5).
7. Remove the reverse lockout collar (4).

1. Rotate the 5th/6th and the reverse shift shaft levers off the shift interlock plate.
2. Remove the 5th/6th and the reverse shift shaft assembly.



3. Remove the countershaft. Lift up the mainshaft enough in order to remove the countershaft.



4. Remove the mainshaft and the shift shaft components as an assembly.

Important: When removing the shift shaft be careful not to lose the dowel pin.

5. Remove the shift shaft assembly from the mainshaft.



6. Remove the input shaft.